Arching metallic profiles in continous in-line process

ABSTRACT

A method and apparatus for manufacturing an arched metallic profile, in a continuous in-line process. The method comprises forming the metallic profile; and arching the formed metallic profile in a continuous in-line process. The apparatus includes a roll forming station configured to receive flat metallic composition and output a given profile. An arching device is configured to receive the metallic profile and bend the metallic profile having a desired radius of curvature wherein a portion of the arching device is displaced with respect to said roll forming station vertically and/or horizontally.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/012,929 filed Dec. 12, 2007 which is herein incorporated by referencein its entirety.

BACKGROUND

1. Field of the Invention

The present invention generally relates to a method and apparatus forroll forming steel. More particularly, the present invention relates toa process and machine for forming arch configurations of metallicprofiles from roll-formed steel during a continuous in-line process.

2. Discussion of Related Art

Continuous in-line processing of steel provides an efficient andrelatively quick method for transforming flat strip steel into steelprofiles to accommodate high volume production with greater uniformityand consistency. This continuous in-line process is well known in theart as disclosed in, for example, U.S. Pat. Nos. 3,122,114 and3,696,503, both to Krengel et. al.; 3,468,145 to Ostrowski; and3,667,095 to Ostrowski et. al., the disclosures of which areincorporated herein by reference. In particular, U.S. Pat. No. 3,122,114disclosed the continuous formation of steel profiles and the galvanizedtreatment of the external surfaces of the formed profiles. U.S. Pat. No.3,696,503 disclosed a method for continuously galvanizing strip steel inwhich a forming roll operation, a galvanizing section and a reformingroll operation were used to produce steel profile having all exposedsurface areas of the strip steel galvanized. In U.S. Pat. No. 3,468,145,a method is disclosed for processing steel having a relatively thickcross-section and producing steel having a desired cross-section bymoving the stock through a mill multiple times. U.S. Pat. No. 3,667,095disclosed an apparatus for the continuous forming, galvanizing andapplication of a protective coating to steel profiles.

Generally, a continuous in-line process first forms strip steel into adesired profile having a cross-section configuration, for example,C-shaped, “U” shaped, etc. The particular steel profile is formed asstraight pieces within a continuous in-line machine and cut to a desiredlength. If the cut steel profiles require a particular radius ofcurvature, the cut profile sections undergo a separate secondary processto form arched sections using, for example, a standard three rollbending machine. However, several drawbacks are associated withperforming the arching process after cutting. First, this additionalarching step of the formed and cut profile sections requires additionallabor, separate process machines and consumes valuable process time.Secondly, if the steel profiles are produced with a plurality of equallyspaced mounting holes along its longitudinal axis, the subsequentarching process may produce undesirable hole elongation along the bendradius area. Thirdly, warping may occur along the bend profile of thesteel profile once sections are arched. Moreover, the cross-section atthe end of the steel profile may change after the steel is bent. Forexample, a steel profile having a “U” shaped cross-section essentiallycomprises a pair of vertically opposed wall members connected by a lowertransverse member. At each longitudinal (i.e. lengthwise) end portion ofthe steel profile, these vertically opposed wall members ideally have acommon transverse plane. Once this “U” shaped profile is arched, one ofthe vertically opposed wall members extends beyond this transverseplane. An additional cutting step is required to ensure that each of the“U” shaped wall members ends on the same transverse plane. This addslabor, time and unwanted material waste to the manufacturing process.Thus, there is a need for a method and apparatus for manufacturing rollformed steel into a particular profile, arching the formed profile andcutting the arched profile all within a continuous in-line process.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention are directed to anapparatus and method for manufacturing arched metallic profiles,particularly steel profiles, using a continuous in-line process. Themethod includes forming the metallic profile; and arching the formedmetallic profile in a continuous in-line process. The apparatus includesa roll forming station configured to receive flat metallic compositionand output a given profile. An arching device is configured to receivethe metallic profile and bend the metallic profile having a desiredradius of curvature wherein a portion of the arching device is displacedwith respect to the roll forming station vertically and/or horizontally.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a block diagram illustrating the steps included in acontinuous in-line process in accordance with the present invention.

FIG. 1B illustrates a diagrammatic view of a continuous in-linearrangement for forming an arch in a steel profile embodying the varioussteps shown in FIG. 1A;

FIG. 2A is a side view of a process for bending a steel profile in acontinuous in-line process in accordance with the present invention;

FIG. 2B is a top plan view of the process for bending a steel profile ina continuous in-line process shown in FIG. 2A in accordance with thepresent invention;

FIG. 2C is a top plan view of the process for bending a steel profile ina continuous in-line process shown in FIG. 2A in accordance with thepresent invention;

FIG. 2D illustrates a cross sectional view of a portion of an archingdevice including an exemplary top insert roller in accordance with thepresent invention; and,

FIGS. 3A and 3B are perspective views of arched metallic profiles formedas part of a continuous in-line forming process in accordance with thepresent invention.

DESCRIPTION OF EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention, however, may be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. In thedrawings, like numbers refer to like elements throughout.

The present invention is directed to a method and apparatus formanufacturing an arched or curved steel profile as part of a continuousin-line forming process. As such, the method roll forms a steel profilefrom strip steel and bends this formed steel profile during thecontinuous movement of the steel through the in-line process in adesired cross-section configuration. Applications of the presentcontinuous in-line process include, for example manufacture of profilesfor storage buildings, greenhouses, boat hulls, canopies, awnings,garages, ponds, swimming pool, structural enclosure elements, furniture,etc. FIG. 1A generally illustrates the continuous in-line roll formingprocess or method in accordance with the present invention. The methodincludes the functions of roll forming strip steels into a desiredprofile at step 100, bending the formed steel profile at step 200 andshearing or cutting the arched steel profile into individual units forshipping at step 300. The bending step 200 employs apparatus 200A andforming device 200B. FIG. 1B illustrates a diagrammatic view of acontinuous in-line arrangement for forming an arch in a steel profileembodying the various steps shown in FIG. 1A. In particular, step 100 inwhich strip steel is roll formed into a desired profile may beaccomplished through the use of an uncoiler 102, end welder 104,accumulation pit 106, punching station 108 and roll forming station 110.Uncoiler 102 is configured to stream out long sections of steel sheet orstrips from coils. The end welder 104 is used to mate the individualsteel sheet sections into a continuous steel sheet length. Theaccumulation pit 106 provides excess length of steel sheet for endwelder 104 to work. The punching station 108 is configured to punchholes or other voids into the continuous steel sheet if desired. Theformed profile may be an open or closed profile. Typical open profilesinclude, for example, “C” shape (most common), “U” shape and angledconfigurations. Typical closed profiles may include such configurationsas polygons, e.g., square, rectangle, triangle and the like, or curvedconfigurations such as oval, circle, and the like. The formed profilemay be either welded or non-welded. The roll forming station 110 rollforms the continuous steel sheet into a particular steel profile.

The step of bending or arching the steel profile includes utilizingTurkshead 202, Turkshead 204 and cutoff guide 206. The step of shearingor cutting 300 the bent steel profile is accomplished using, forexample, a flying cutoff assembly 302. As will be described in moredetail below with reference to FIGS. 2A-2C, a Turkshead may remainstationary in an angular or vertically displaced position relative toroll forming station 110 as the steel is feed through the process lineto provide a constant radius of curvature to the formed steel profileprior to cutting. Alternatively, the Turksheads 202 and 204 may besynchronized for linear and/or angular displacement with respect to theroll forming station 110 as the steel profile is shaped, providing avariable radius of curvature. As such, variable radii may be formedwithin a single cut steel profile or different radii may be formed indifferent cut lengths of steel profile. The bent formed steel profileforms an arch, which may include either a singular arch or multiplearches. Multiple arches may also be formed where the arches are withinthe same plane having different radii, or arches within different planesof formations, whether the arch has the same radius or different radiithan other arches in different planes. In addition, the steel profilemay be arched by the bending profile step 200 to form: (i) a consistentarch, (ii) multiple arches within more than two dimensions, (iii)different arches in the same direction, (iv) different arches indifferent directions, or (v) a spiral configuration. In this manner,various combinations or arch radii, profile forms and section lengthsmay be implemented using the present invention as described below.

FIG. 2A illustrates an exemplary process line 10 mounted on a base 5 forforming steel profiles from strip steel. In particular, strip steel issupplied by an uncoiler which rotates to feed the continuous flat steel111 to roll forming station 110. The strip steel may include a pluralityof holes, varying in hole location, size, shape, or combinationsthereof. Roll forming station 110 defines a steel profile forming deviceand includes a plurality of roll forming stands 115 ₁-115 _(N) in whichthe strip steel is roll formed to a profile. The roll forming stands arepositioned along the process line aligned with a central axis (denotedas “A” in FIG. 2B) to produce a straight rolled steel profile. Each rollforming stand includes a plurality of rolls which engage both the upperand lower surfaces of the strip steel 111 and apply pressure thereto tobend the steel. The axis of rotation of each roll is transverse to thedirection that the strip steel moves through process line 10. Certain ofthe plurality of roll forming stands 115 ₁-115 _(N) may be configured tohave either an upper or lower combination of rolls which remain fixedrelative to the direction of movement through the process line. Thenumber of roll forming stands 115 ₁-115 _(N) will depend on the desiredshape of the steel profile where each stand works or bends the flatsteel progressively until the desired shape or profile is achieved. Forexample, strip steel 111 is supplied to first roll forming stand 115 ₁where it is rolled and output as steel 111 ₁. The next roll formingstand in the process 115 ₂ receives the formed steel 111 ₁ where it isagain rolled to output steel 111 ₂. The next roll forming stand in theprocess 115 ₃ receives the formed steel 111 ₂ where it is again rolledto output steel 111 ₃. As can be seen in FIG. 2A, the steel outputted byeach roll forming stand produces a changed profile which is rolled inprogressive increments by the next successive roll forming stand instation 110. This process continues until the desired cross-section ofsteel profile 111 _(N) is outputted by the last roll forming stand 115_(N) in the process line 10. By way of example, a simple “U” shapedsteel profile or cross-section may require six roll forming stands (115₁-115 ₆) and a more complex shape such as a “U” shape with channel edgesmay require twelve to 18 roll forming stands (115 ₁-115 ₁₈). In additionto forming the desired profile of the formed steel, the rollers in eachstand also act to move or advance the strip steel through the processline 10.

Once the steel has been formed into a desired profile, a pair ofTurksheads 202 and 204 are disposed between the last roll forming stand115 _(N) and the cutoff assembly 302. The Turksheads 202 and 204 definean arch forming device (200B of FIG. 1A). In particular, Turkshead 202receives the formed steel profile 111 _(N) from roll forming stand 111_(N). The Turksheads 202 and 204 impart sufficient force to the steelprofile to arch the profile in a desired direction. Each Turkshead 202and 204 includes individual rollers or roll clusters rigidly held withina rotary housing. Representative Turksheads include, for example withoutlimitation, Turksheads similar to Model Number TH-500-SSU available fromAddison Machine Engineering Inc. of Reedsburg, Wis. The formed steelprofile 111 _(N) is arched by the Turksheads 202 and 204 to a desiredbend radius to form profile 111 _(T). The arched steel profile 111 _(T)is then cut to desired lengths by cutoff assembly 302 to form cut steelprofile section 111 _(C). In order to perform the bending step 200,either Turkshead 202 and/or Turkshead 204 may be disposed linearly inthe vertical Y direction through the use of movable platforms 225 and228 respectively. In particular, as steel profile 111 _(T) engagesTurkshead 204 at the desired location along the profile's longitudinalaxis, platform 228 displaces Turkshead 204 vertically with respect toTurkshead 202 which remains stationary. This displacement of Turkshead204 defines a bend point incident on Turkshead 202 causing an arching ofsteel profile 111 _(T) along its longitudinal axis to produce profile111A. Similarly, Turkshead 202 may be disposed on a movable platform 226such that Turkshead 202 is disposed linearly in the vertical Y directionwith respect to roll station 111 _(N) and Turkshead 204. Thisdisplacement of Turkshead 202 defines a bend point incident on the lastroll stand 111 _(N). The displacement (linearly or angularly) of eitherTurkshead 202 and/or 204 with respect to last roll station 111 _(N)causes an arching of steel profile 111 _(T) along its longitudinal axisto produce steel profile 111 _(A) which is supplied to cut-off assembly302 where it is cut into desired lengths.

Turksheads 202 and 204 may also be configured to be displaced angularlya distance in direction X off the central axis “A” formed by the rollforming stands 115 ₁ . . . 115 _(N) in process line 10 as described ingreater detail with reference to FIGS. 2B and 2C. In this manner, theTurksheads 202 and 204 provide a constant radius of curvature for thesteel profile formed by roll forming station 110 prior to cutting bycut-off assembly 302 within the continuous in-line process.Alternatively, the Turksheads 202 and 204 may be synchronized to move asthe steel profile is shaped by the roll assembly 110 thereby providing avariable radius of curvature. In addition, cut-off assembly 302 is alsomovable on platform 301 such that cut-off assembly 302 must be in-linewith Turkshead 204 to provide an end cut along a common transverseplane. In other words, cutoff assembly 302 is perpendicular to the steelprofile being roll formed by station 110. An exemplary C-shaped steelprofile was formed using the above described continuous in-line processwith a web width of 70 mm, a leg height of 50 mm, and a return length of10 mm. Once formed, and as a part of the in-line continuous process, thesteel profile was driven through a Turkshead to create an arch with anouter radius of 12.5 meters, and an overall length of 4.2 meters. Oncebent, the steel profile was cut to the desired length.

The Turkshead 202 and/or 204 may also include a forming device 200B toprovide support and/or restrain the desired profile in criticallocations during the arching process. In particular, when the archingprocess engages the movement of Turkshead 204 while Turkshead 202remains stationary, the stress on the profile about its bend point maycompromise the integrity of the formed profile. Thus, a support guide orguide plate is used to alleviate these bend forces incident on theformed profile. For example, a guide plate or a Turkshead guide roll cutdevice has the corresponding shape of profile 111 _(N) undergoing thearching process and may be positioned within Turkshead 202. This deviceis used to support the steel profile during arching while avoidingdamage to the given cross-section of the profile as it passes throughthe process line. In this manner, the forming device (200B) ispositioned to best enhance the structural integrity of the steel profileand provides a stabilizing effect while the steel profile is beingarched or bent. These forming devices may be provided in specifiedshapes, or contact along specified locations of the steel profile andare generally used in the formation of bends in open profiles, such asbeing shaped to fit in, and conform to, a given internal space withinthe steel profile. This forming device 200B may be separate from orincorporated into the Turkshead(s) to contribute to the forming of theprescribed curve while maintaining the desired profile. Alternatively,the forming device 200B may be part of or in juxtaposition to cutoffassembly 302 to contribute to the forming of the prescribed curve whilemaintaining the desired profile and to promote the unimpeded operationof the cutoff assembly 302. For example, a forming device may be used inbending a C-shape in conjunction with a Turkshead by providing aresistive force to pull against the inside of the C-shape duringbending, e.g., having four rolls providing pressure on a side member ofthe steel profile to force it in a certain direction while minimizingwrinkles in the steel profile.

FIG. 2B is a top plan view of the process line 10 shown in FIG. 2Ahaving a plurality of roll forming stands 115 ₁-115 _(N) centrallydisposed along axis A to better illustrate the angular displacementfeature of bending or arching step 200. Strip steel 111 is supplied tofirst roll form stand 115 ₁ and the process of roll forming proceeds asdescribed above to produce a desired steel profile 111 _(N). Turkshead202 remains stationary and Turkshead 204 is displaced angularly adistance Δ from the central axis “A” such that a bend radius “R” isformed in the steel profile. The distance may be varied during theforming of the steel profile using roll forming station 110 to form aprofile with multiple radius of curvatures. As Turkshead 204 isdisplaced, a different degree of arch is imparted into the steelprofile. This movement is controlled to account for the speed of theprocess, amount of bend within a steel profile, and repetition of theprocess to reproduce similar steel profiles consecutively havingcorresponding degrees of arch therein. Preferably, the process may beused to create dissimilar sets of steel profiles, where each set ofprofiles are formed as a set, that may be used together, e.g., the leftand right rails (mirror sides) of a slide, etc. In this manner, theconstituents of a particular steel profile set are manufactured with ahigh degree of accuracy for use together. Once the profile is arched,the profile is supplied to cut-off assembly 302 which is angularlyaligned with Turkshead 204 to cut the arched steel profiles into desiredlengths.

FIG. 2C is a top plan view of the process line 10 shown in FIG. 2B whereboth Turksheads 202 and 204 are displaced angularly with respect to axis“A” to form another arched configuration of steel profile. Inparticular, Turkshead 202 is displaced angularly a distance Δ₁ from thecentral axis “A” such that a bend radius is formed in the steel profilewith respect to bend station 115 _(N). Turkshead 204 may also bedisplaced angularly a distance Δ₂ from the central axis “A”. In thismanner, a steel profile having an arching radius of curvature “R” may betailored to a particular configuration. Cutoff assembly 302 receives thearched steel profile and cuts the profiles into desired lengths. Again,cutoff assembly 302 is aligned with Turkshead 204 to provide an end cutalong a common transverse plane of the steel profile. The relationshipof the distances Δ₁ and Δ₂ will depend on the desired radius ofcurvature of the profile to be arched. FIG. 2D illustrates a crosssectional view of a profile through Turkshead 204 and an exemplary topinsert roller 250 disposed with Turkshead 204. Insert roller 250 isincluded in the top section of Turkshead 204 to maintain the shape ofthe roll formed profile 111 _(T) during the arching step to equalize thelongitudinal stress on the profile during arching to preventkinking/warping thereof. In particular, roll formed profile 111T isdisposed between Turkshead side rollers 251A and 251B for bending.Insert roller 250 is configured to engage profile 111T such that as theprofile is being arched, end 250A of insert roller 250 cooperates withthe profile to maintain shape thereof. Insert roller 250 shown in FIG.2D is an exemplary shape for profile 111T and may be exchanged withinTurkshead 204 to accommodate other profile shapes.

The degree of bend or arch within the steel profile is determined by thevertical and/or angular displacement of Turkshead 202 and/or Turkshead204. Representative bends include, for example, arch ranges in radiusfrom about 3 meters to about 24 meters. As seen in FIGS. 3A and 3B, theformed arch may include a bend along the sides of the steel profile,such as that shown as a simple arch in FIG. 3A, or a reverse archingstructure with varying degrees of arch, shown in FIG. 3B. Representativedimensions of the steel profile may include a web width of from about1.5 inches to about 6 inches. Representative arch ranges have a radiusfrom about 3 meters to about 24 meters. Although bends within the steelprofile may include a variety of configurations, the bent formed steelprofile preferably forms an arch. The formed arch preferably has aconsistent radius. Consistent radius include those radii having aminimal deviation along a given length of formed steel profiled withrepresentative deviations ranging from about ⅛^(th) of an inch to about½ inch. The arch may be in the form of a singular arch or multiplearches, with a singular arch preferred. Representative multiple archesinclude multiple arches within more than two dimensions, differentarches in the same direction and different arches in differentdirections. The arch may be formed into a full circle structure, whichmay be formed using guides that offset the feed out of the bending steelprofiles outside of the plane of the circle, prior to being cut.Examples of the final steel profiles, include for example withoutlimitation, spirals, circles, slides, S-shapes, and the like.

During the in-line continuous process the arched steel profile is cut orsevered by assembly 302 after the steel profile has been arched. Thisavoids drawbacks associated with prior methods where the steel profileswere first cut to length and then arched or bent to a desired radius ofcurvature pursuant to a secondary process. Accordingly, the method andapparatus of the present invention forms a bent steel profile productcontinuous in-line at high production rates. Representative productionrates include, for example, from about 50 ft/min to about 500 ft/min,with rates of from about 60 ft/min to about 2040 ft/min preferred, andrates from about 60 ft/min to about 90 ft/min most preferred. Supportsat the cutoff assembly may be located on the side rail to move theweight load of the steel profile off of the blade. Additionally, thesesupports may be used to push at the bottom or top of the steel profileto reduce twist, or increase the arch. Although steel profiles arepreferred and referred to herein, other metallic compositions may beused in the formed profiles to be arched. For example, when aluminumprofiles are manufactured, formed profiles may result from an extrusionprocess prior to being bent in the continuous in-line process. Othermetals may be used, which are generally designed as specific functionalcomponents.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations and changes to thedescribed embodiments are possible without departing from the sphere andscope of the present invention, as defined in the appended claims.Accordingly, it is intended that the present invention not be limited tothe described embodiments, but that it has the full scope defined by thelanguage of the following claims, and equivalents thereof.

1. A method for manufacturing an arched metallic profile in a continuousin-line process comprising the steps of: forming the metallic profile;and, arching the formed metallic profile.
 2. The method of claim 1,further comprising the step of stabilizing the steel profile.
 3. Themethod of claim 2, wherein the step of stabilizing the steel profile ispreformed in conjunction with a Turkshead.
 4. The method of claim 2,wherein the step of stabilizing the steel profile is preformed inconjunction with a cutoff assembly.
 5. The method of claim 1, furthercomprising the step of: forming holes within the strip steel prior toforming the steel profile.
 6. The method of claim 1, wherein themetallic profile is selected from the group of a steel profile, andaluminum profile, and combinations thereof.
 7. The method of claim 6,wherein the step of forming the metallic profile includes the step of:forming a steel profile from a strip steel in a continuous roll formingprocess.
 8. The method of claim 6, wherein the bent formed steel profileforms multiple arches.
 9. The method of claim 6, wherein the bent formedsteel profile forms multiple arches within two or more distinct planes.10. The method of claim 9, wherein the bent formed steel profile formsdifferent arches in the same direction.
 11. The method of claim 9,wherein the bent formed steel profile forms different arches indifferent directions.
 12. The method of claim 1, further comprising thestep of: cutting the bent steel profile within the in-line continuousprocess.
 13. An apparatus for bending metallic profiles within acontinuous in-line process comprising: a roll forming station configuredto receive flat metallic composition and output a given profile; and anarching device configured to receive said metallic profile and bend themetallic profile having a desired radius of curvature wherein a portionof said arching device is displaced with respect to said roll formingstation.
 14. The apparatus for bending metallic profiles of claim 13wherein said roll forming station comprises a plurality of rollstations, each of said roll stations including rollers configured toreceive the metallic composition and successively bend the compositioninto the given profile.
 15. The apparatus for bending metallic profilesof claim 13 wherein said arching device comprises at least oneTurkshead.
 16. The apparatus for bending metallic profiles of claim 13further comprising a cutting assembly configured to receive said archedprofile and cut said profile into particular lengths.
 17. The apparatusfor bending metallic profiles of claim 15 further comprising a supportguide disposed within said Turkshead about which said metallic profileis arched.
 18. The apparatus for bending metallic profiles of claim 13wherein said arching device is displaced linearly with respect to saidroll forming station.
 19. The apparatus for bending metallic profiles ofclaim 13 wherein said arching device is displaced angularly with respectto said roll forming station.
 20. The apparatus for bending metallicprofiles of claim 15 wherein said Turkshead is a first Turkshead, saidarching device further comprising a second Turkshead disposed betweensaid first Turkshead and said roll forming station.
 21. The apparatusfor bending metallic profile of claim 20 wherein said second Turksheadincludes an insert roller device corresponding to a shape of saidprofile, said insert roller device configured to equalize a longitudinalstress incident on the profile during arching.